Tribological properties of YSZ and YSZ/Ni-YSZ nanocomposite coatings prepared by electron beam physical vapour deposition

Metal-ceramic nanocomposite coatings have been applied to many industrial applications owing to their remarkable properties such as wear, corrosion and high temperature oxidation resistance than that of metals and alloys in high temperature environments. In this study, YSZ and Ni-YSZ nanocomposite coatings deposited by electron beam physical vapour deposition (EBPVD) for high temperature environments have been investigated. Initially friction and wear behaviour of YSZ coatings deposited at various substrate temperature were studied. Then the effect on wear response of Ni-YSZ nanocomposites with different Ni content were investigated using a ball-on-disc micro tribometer. The structural and tribochemical changes that occurred in the wear tracks of YSZ and Ni-YSZ coatings were investigated using field emission scanning electron microscopy and Raman spectroscopy. The results obtained on sliding wear and friction behaviour of these nanocomposite coatings suggest that 50 wt.% of Ni in YSZ nanocomposite provides good wear resistance behaviour than that of other coatings. Such an improvement in tribomechanical and wear performance of the nanocomposite coating could be attributed to the optimum amount of Ni which promotes the formation of NiO from Ni due to the frictional heat between nanocomposite coating and the sliding counter body in wear track as confirmed by Raman analysis.     

Investigation of tribological properties of micro-arc oxidation ceramic coating on Mg alloy under dry sliding condition

To enhance wear resistance of Mg alloy, micro-arc oxidation (MAO) ceramic coatings on Mg substrate were prepared in silicate electrolyte under various currents. It was found that the surface roughness and thickness of MAO coating were increased with the increase of current. The dry tribological tests showed that the friction coefficient and wear resistance of thicker coatings (obtained under currents of 3?A and 4?A) were much higher than that of Mg alloy and the thin coating (obtained under current of 2?A), meanwhile the lifetime of the coating obtained under 4?A was longer than the other coatings under higher load. The wear type of thin MAO coating was slight abrasive wear under low load, whereas translated to severe adhesive wear under high load. While the main wear mechanism of thick MAO coating was slight abrasive wear or scratch under the given test condition, which was attributed to the thick intermediate layer improved load support for the soft substrate. The tribological study indicated that the MAO coating obtained under 4?A current had better wear resistance and life time due to its compact microstructure and thickness.     

Al2O3/Si3N4 nanocomposite coating on aluminum alloy by the anodizing route: Fabrication,characterization, mechanical properties and electrochemical behavior

An Al₂O₃/Si₃N₄ nanocomposite coating was successfully fabricated on commercial aluminum alloy. Hardness measurements, polarization and electrochemical impedance spectroscopy (EIS) were employed to study the mechanical and corrosion behaviors of the coatings. Field-Emission Scanning Electron Microscopy (FE-SEM) equipped with Energy Dispersive Spectroscopy (EDS) and X-ray diffraction (XRD) were utilized to characterize the surface morphology and phase composition of the coatings. Also, coatings abrasive wear properties were evaluated with a modified ASTM G105 standard. FE-SEM image, EDS and XRD analysis revealed the presence of Si₃N₄ in the coating. Furthermore, the results showed hardness of the coatings to increase from 380±50 HV for the anodized layer to 712±36 HV for the composite coatings that were formed in an electrolyte containing 6 gr/lit Si₃N₄ nanoparticles. Electrochemical measurements indicated that corrosion resistance of the nanocomposite coating significantly increased compared to the anodized coating. In addition, the effect of Si₃N₄ nanoparticles into the nanocomposite coatings on abrasive wear mechanism and mass loss rate of the coatings was investigated.     

再生PC的表面耐磨改性研究

以从工业固废中分选出的废旧透明聚碳酸酯（RPC）为原料制备了再生透明PC板材（RPC-SH）,分别选用有机硅类（STC2000）和丙烯酸类（SY-5223）透明耐磨涂层对RPC-SH进行表面加硬处理,得到加硬板材Si-RPC-SH和SY-RPC-SH。分别对3种板材进行涂层稳定性、表面耐刮擦性能、透明性能和力学性能测试。结果表明,两种涂层均能与PC透明板材表面良好结合,附着力等级达到1级,具备一定抵抗热水、酸、碱、盐侵蚀的能力;经过表面加硬处理后,再生透明PC板材的铅笔硬度从5B分别提高到H和HB,负载砝码后的磨耗失重更小,表面耐磨性和耐刮擦性能获得显著提升;由于涂层具有更低的光折射率,加硬板材Si-RPC-SH和SY-RPC-SH透光率相对于RPC-SH均略有增强,雾度下降;由于涂层中有机溶剂的影响,加硬板材力学强度相对于再生透明PC板材有所下降。     

Microhardness and wear resistance of Al2O3-TiB2-TiC ceramic coatings on carbon steel fabricated by laser cladding

Al₂O₃-TiB₂-TiC ceramic coatings with high microhardness and wear resistance were fabricated on the surfaces of carbon steel substrates by laser cladding using different coating formulations. The microstructures of these ceramic coatings with the different coating formulations were investigated using X-ray diffraction, scanning electron microscopy, and energy dispersive spectrometer. The wear resistance and wear mechanism were analyzed using Vickers microhardness and sliding wear tests. The results showed that when the amount of independent Al₂O₃ was increased to 30%, the ceramic coatings had a favorable surface formation quality and strong metallurgical bond with the steel matrix. The cladding layer was uniformly and densely organized. The black massive Al₂O₃, white granular TiB₂, and TiC distributed on the Fe substrate significantly increased the microhardness and wear resistance. The laser cladding ceramic coating had many hard strengthening phases, and thus resisted the extrusion of rigid particles in frictional contact parts. Therefore, the wear process ended with a “cutting-off” loss mechanism.     

Improving the mechanical resistance of waterborne wood coatings by adding cellulose nanofibres

In the present study, microfibrillated cellulose (MFC) and nanocrystalline cellulose (NCC) were applied as additives for a waterborne acrylate/polyurethane-based wood coating in order to improve the mechanical resistance of coated wood surfaces. Coating mixtures containing up to 5 wt% nanocellulose were prepared by high-shear mixing and applied to wood substrates. The optical, mechanical and chemical properties of cured coatings were characterized. Surface roughness, gloss, scratch resistance, abrasion resistance and resistance against chemicals were determined according to the relevant European standards. Additionally, nanoindentation (NI) was used to assess the micromechanical properties of modified and unmodified coatings. Owing to a higher surface roughness, cellulose-filled coatings showed significantly lower levels of gloss than the unmodified coating indicating that nanocellulose acts as a matting agent. NI experiments revealed a slightly positive effect of nanocellulose addition on the hardness and modulus of the coatings. While scratch resistance improved consistently with increasing nanocellulose addition, abrasion resistance was found to improve only sporadically. Tensile tests on free-standing coating films revealed a significantly higher tensile strength and modulus for cellulose-filled coatings. Overall, the results suggest that the addition of cellulose nanofibres primarily improves the internal cohesion of the coating layer whereby MFC was more effective than NCC.     

化学镀制备高耐蚀耐磨Ni-P-SiC复合镀层

研究了Ni-P-SiC复合镀层的制备工艺和性能以及SiC含量对镀层性能的影响。采用Taber试验机对Ni-P-SiC复合镀层的磨损性能进行了测试,并用VHX-100型三维视频显微镜对磨损形貌进行了观察,分析了复合镀层的磨损机理。结果表明:SiC颗粒的加入能有效地降低摩擦副之间的犁沟效应及摩擦表面发生粘着的面积,从而减少镀层的磨损。采用电化学实验等手段研究了Ni-P-SiC复合镀层的耐蚀性能。当复合镀层均匀一致,能起到一个良好的屏蔽作用时,耐蚀性十分优异;而镀层缺陷的存在将导致耐蚀性能降低。     

Nylon 11/silica nanocomposite coatings applied by the HVOF process. II. Mechanical and barrier properties

Nylon 11 coatings filled with nominal 0–15 vol % of nanosized silica or carbon black were produced using the high velocity oxy‐fuel combustion spray process. The scratch and sliding wear resistance, mechanical, and barrier properties of nanocomposite coatings were measured. The effect of powder initial size, filler content, filler chemistry, coating microstructure, and morphology were evaluated. Improvements of up to 35% in scratch and 67% in wear resistance were obtained for coatings with nominal 15 vol % contents of hydrophobic silica or carbon black, respectively, relative to unfilled coatings. This increase appeared to be primarily attributable to filler addition and increased matrix crystallinity. Particle surface chemistry, distribution, and dispersion also contributed to the differences in coating scratch and wear performance. Reinforcement of the polymer matrix resulted in increases of up to 205% in the glass storage modulus of nanocomposite coatings. This increase was shown to be a function of both the surface chemistry and amount of reinforcement. The storage modulus of nanocomposite coatings at temperatures above the glass transition temperature was higher than that of unfilled coatings by up to 195%, depending primarily on the particle size of the starting polymer powder. Results also showed that the water vapor transmission rate through nanoreinforced coatings decreased by up to 50% compared with pure polymer coatings. The aqueous permeability of coatings produced from smaller particle size polymers (D‐30) was lower than the permeability of coatings produced from larger particles because of the lower porosities and higher densities achieved in D‐30 coatings. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 78: 2272–2289, 2000     

‎Deposition of Ni-tungsten carbide nanocomposite coating by TIG ‎welding: Characterization and control of microstructure and wear/corrosion responses‎

In this study, the effect of the amount of tungsten carbide nanoparticles on the wear and corrosion properties of Ni-tungsten carbide nanocomposite coating which is deposited on steel St37 by Tungsten Inert Gas (TIG) welding was evaluated. For this purpose, surface alloying was firstly conducted on St37 steel by using TIG process with a current of 150 Amps using pure nickel powder and tungsten carbide reinforcement nanoparticles (in 5, 10, 15 and 20 wt%). Then, Transmission Electron Microscopy (TEM), optical microscope, Field Emission Scanning Electron Microscopy (FE-SEM), Energy Dispersive Spectroscopy (EDS), X-ray Diffraction (XRD), microhardness test by Vickers method, abrasion test by sweep method, and electrochemical tests (potentiodynamic polarization and electrochemical impedance spectroscopy) were used in order to characterize the microstructure and tribological properties of the deposited layers. Microstructural observations showed that the deposited Ni-tungsten carbide nanocomposite coating have a dendritic microstructure with a uniform distribution of tungsten carbide nanoparticles, which reduced the dendritic size by increasing the amount of tungsten carbide nanoparticles. The results of this study showed that by increasing the amount of tungsten carbide nanoparticles in the Ni- tungsten carbide nanocomposite coating, the hardness (from the coating surface to the interface of coating/substrate) and wear resistance increased sharply, but the corrosion resistance decreased. Also, the evaluation of the wear mechanism showed that by increasing the amount of tungsten carbide nanoparticles in Ni-tungsten carbide nanocomposite coatings, the wear mechanism in this coating changed from complex abrasive-sheet like to complex adhesive-oxidation.     

“Effect of nano-ZnO particles on the corrosion behavior of alkyd-based waterborne coatings”

A nano-composite was formed by incorporating nano-ZnO in a specially developed alkyd-based waterborne coating to different loading levels. The nano-ZnO based composite coatings were applied on mild steel substrate by dipping. The coated panels were subjected to various test environments like salt-spray, humidity, UV and mechanical tests like scratch and abrasion. The improvement in electrochemical performance and mechanical properties of the composite coatings were evaluated using various analytical techniques. FTIR technique was used to investigate the interaction between nano-ZnO particles and the polymer functionalities. Differential scanning calorimetry (DSC) was done to study the curing behavior of nano-composite coatings. SEM and AFM were used to investigate dispersion of nano-ZnO particles and the changes in the surface behavior of the coatings before and after exposure to the test environment. The result showed that, with increase in the concentration of nano-ZnO there was an improvement in the corrosion resistance, UV resistance and mechanical properties of the coatings indicating the positive effect of addition of nano-ZnO particles in the coatings.     

W-Ni-Fe合金镀层与硬铬镀层耐磨性的对比试验

国内煤矿机械设备常采用镀铬的方法来提高工件表面的耐磨性,本文在27SiMn钢基体上制备了W-Ni-Fe合金镀层和硬铬镀层,利用显微硬度计、厚度仪等测试了硬铬和镍-铁-钨合金两种镀层的硬度、厚度,并用摩擦磨损试验机测试了两种镀层的耐磨性能并分析了实验结果。实验结果表明:在相同环境和试验条件下,热处理后的W-Ni-Fe合金镀层硬度不亚于硬铬镀层,且在一定载荷范围内,其耐磨性能优于硬铬镀层。     

Hard coatings on elastomers for reduced permeability and increased wear resistance

Abstract

In this study, three different elastomers, namely hydrogenated nitrile butadiene rubber, fluoroelastomer and silicone, have been subjected to two different hard metallised coatings by ion implantation process. The three different elastomers are commonly used in various seal applications, where reduced wear and gas permeability are essential in maintaining seal performance and functionality. Samples of these rubbers have been coated with chromium coating in one set of tests. In the second set of tests, samples of elastomers have been coated with tungsten carbide coating being deposited on all the three different elastomers. Wear, gas permeability and mechanical behaviour of the coated samples were compared with each other and with the control uncoated elastomers. All the coated samples showed good reduction in gas permeability. With the use of metallised coatings, there has been improved resistance to wear in all the coated samples. Adhesion strength and effect of coating on the elastomer have been investigated by mechanical testing. Mechanical tests revealed good adhesion of metal coatings on all the rubber samples, and there was no detrimental effect on the mechanical properties after coating.     

Development of Scratch- and Abrasion-Resistant Coating Materials Based on Nanoparticles,Cured by Radiation

The aim of this study was to compare the effect of monomers, prepolymers, and nanosilica on the scratch and abrasion resistance of nanocomposite coatings. Ultraviolet (UV) and electron beam (EB) curing were used to cure the nanocomposite coatings. The effect of monomers, prepolymers and nanosilica particles on the viscosity, pendulum hardness, gel content, scratch and abrasion resistance were studied. It was found that the optimum formulation for scratch and abrasion resistance contained 15% Ebecryl 600 epoxy acrylate resin with 30% monomer PETIA and 30% of Aerosil OX-50 nanosilica.     

金属基耐高温陶瓷涂层抗热冲击性能的研究

为提高金属基陶瓷涂层的抗热冲击性能，以无机胶粘剂磷酸二氢铝、耐磨陶瓷骨料氧化铝、碳化硅和氧化镁混合后涂覆于金属表面制得陶瓷涂层。通过交替加热及冷却试验测试该陶瓷涂层的抗热冲击性能，并与其他人的研究数据进行比较。所得涂层抗热冲击次数超过10次，超过了其他人的实验数据，这是由于涂层与基体在界面处相互扩散形成过渡层。另外，宏观上的机械联锁有利于提高涂层与基体在界面处的结合，从而提高了其抗热冲击性能。     

丙烯酸酯聚氨酯/SiO2纳米复合涂层结构与形态对其耐刮伤性影响研究

以四乙氧基硅烷(TEOS)作为主要前驱体,通过改变溶胶-凝胶工艺参数制得了结构和形态各异的丙烯酸酯聚氨酯/SiO2纳米复合涂层,利用TEM、SAXS等手段表征涂层的结构与形态,由洗刷前后涂层的失光率来表征耐刮伤性,详细探讨了纳米复合涂层耐刮伤性与SiO2相特征、有机无机相作用力及SiO2质量分数之间的关系。研究表明:丙烯酸酯聚氨酯涂层中引入纳米SiO2相后,耐刮伤性明显提高。有机相与SiO2相之间的作用力是影响涂层耐刮伤性的最重要因素,作用力越强,耐刮伤性越好。网络状纳米SiO2与颗粒状纳米SiO2相比,更有利于耐刮伤性的提高,且网络状纳米SiO2质量分数越大,耐刮伤性越佳,但SiO2相的致密度和尺寸对耐刮伤性影响较小。对于颗粒状胶体SiO2,在15~160 nm范围内,粒径对耐刮伤性没有明显影响;随着胶体SiO2粒子的质量分数增加,耐刮伤性先增大后减小。     

粘结剂对超音速火焰喷涂碳化钨涂层磨粒磨损性能的影响

采用超音速火焰喷涂(HVOF)工艺在35钢基体上制备了WC-10Ni涂层和WC-12Co涂层,研究了镍、钴这两种粘结剂对WC涂层的显微硬度、摩擦系数和抗磨粒磨损性能的影响,采用扫描电子显微镜观察涂层磨损前后的表面形貌,探讨了WC涂层的磨粒磨损机理。结果表明,以HVOF方法制备的2种WC涂层均有较高的显微硬度,WC-10Ni涂层和WC-12Co涂层与SiC砂纸摩擦副之间的干摩擦系数相差不大。2种涂层在低载荷下均有较好的抗磨粒磨损性能,但在较高载荷下WC-12Co涂层的抗磨性明显优于WC-10Ni涂层。2种涂层的磨粒磨损形式主要为均匀磨耗磨损,磨损机理以微切削和微剥落为主。WC-12Co涂层的磨损表面损伤较轻微,综合性能优于WC-10Ni涂层。     

Synthesis and evaluation of TaC nanocrystalline coating with excellent wear resistance,corrosion resistance,and biocompatibility

To improve the mechanical properties, corrosion resistance, and biocompatibility of implanted titanium alloys, a TaC nanocrystalline coating was deposited on Ti–6Al–4V alloy using a double-cathode glow discharge method. The microstructure of the newly developed coating was characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The coating exhibits a dense and uniform structure, composed of equiaxed TaC grains with an average grain size of 15.2 nm. The mechanical properties of the TaC-coated Ti–6Al–4V alloy were evaluated by a scratch tester, a nanoindentation tester, and a ball-on-disc tribometer. The average hardness of the TaC nanocrystalline coating is about 6 times higher than that of uncoated Ti–6Al–4V alloy and the specific wear rate of the coating is two orders of magnitude lower than that for Ti–6Al–4V at applied normal loads of 4.9 N under dry sliding condition. The electrochemical behavior of the TaC nanocrystalline coating after soaking in Ringer's solution for different periods was investigated by potentiodynamic polarization and electrochemical impedance spectroscopy (EIS). Furthermore, in vitro cytocompatibility of the coating was assessed using MC3T3-E1 mouse osteoblastic cells. The results showed that the TaC coating exhibits better corrosion resistance and biocompatibility as compared to uncoated Ti–6Al–4V alloy.     

Submicrometer characterization of surfaces of epoxy‐based organic–inorganic nanocomposite coatings. A comparison of AFM study with currently used testing techniques

Surface properties (morphology, hardness) of transparent colorless epoxy‐based organic–inorganic nanocomposite coatings were investigated by atomic force microscopy, optical and scanning electron microscopy, nanoindentation, and the Persoz pendulum test. Friction and wear coefficients were obtained from tribological experiments. The influence of mechanical properties and the size, shape, and concentration of additives (colloidal silica particles and montmorillonite sheets) on the measured surface characteristics are discussed. It was found that the highest surface hardness (assigned by nanoindentation, pendulum test or expressed as the scratch resistance) exhibited materials with the glass‐transition temperature close to 20°C. Microcopy techniques revealed that surface morphology is influenced by both types of admixtures: on the nanometer scale by colloidal silica particles and on micrometer scale by montmorillonite platelets. Already 1 wt % of montmorillonite increased friction coefficients and wear resistance without distinctive changes of tensile properties. However, the addition of ? 20 wt. % of silica nanoparticles was necessary for the increase of wear and scratch resistances. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102:5763–5774, 2006     

UV-waterborne polyurethane-acrylate nanocomposite coatings containing alumina and silica nanoparticles for wood: mechanical, optical, and thermal properties assessment

The effect of alumina and silica nanoparticles on mechanical, optical, and thermal properties of UV-waterborne nanocomposite coatings was investigated. The addition of nanoalumina and nanosilica was shown to decrease the hardness because of nanoparticle aggregation. In comparison to the neat coating and despite the presence of aggregates, the scratch resistance of nanocomposite coatings was significantly improved. As expected, the gloss of UV-waterborne coatings was reduced following the addition of nanoparticles due to an increase of the surface roughness. Alumina and silica nanoparticles were found to enhance the glass transition temperature of PUA nanocomposite coatings by hindering the mobility of macromolecular chains at the interface around the nanoparticles. Finally, the interest and efficiency of grafting trialkoxysilanes was demonstrated with the study of nanosilica behavior. Not only was the dispersion of nanosilica enhanced following trialkoxysilanes grafting onto silica nanoparticles, but also the scratch resistance and the adhesion of UV-waterborne coatings containing nanosilica markedly increased even with 1 wt% content. Silica which is recommended in the wooden furniture and kitchen cabinet manufacturing industry as nano-reinforcement provides improved properties well suited in surface coating applications to efficiently protect surface of wood substrates.     

Cracking induced tribological behavior changes for the HVOF WC-12Co cermet coatings

HVOF sprayed WC based cermet coatings have been widely used in industries as barriers against wear and hydrodynamic cavitation due to their high hardness and relatively high toughness. However, cracking of the coatings can occur during coating production or in service, which can reduce operational performances. It can be difficult to assess the performance impact due to cracks within the coating and as to whether the cracked coatings should be resprayed or removed from service. In this work, artificial cracks of different widths were introduced to liquid fuel HVOF sprayed WC-12Co coating through uniaxial tension of the coated steel substrate to assess the implications of such cracking. Tribological performances of the cracked coatings were examined using rubber wheel dry abrasion, ‘ball on disc’ sliding wear, and ultrasonic cavitation erosion. The results show that the crack deteriorates the abrasive wear resistance of the coating at the initial stage due to preferable mass loss at the cracks. However, after 30?min of abrasion, all the cracked coatings showed the same wear rate as compared to the non-cracked coating, with the abrasive wear resistance acting independent to the crack characteristics. Because the cracks could store wear debris and thus minimize the debris induced abrasion to the coating surface during sliding wear test, both improvement in wear resistance and reduction in coefficient of friction (COF) were detected in the cracked coatings. During the cavitation test, it was found that the mass loss of the specimen increased significantly (up to 75%)with crack width and density suggesting that the crack presence greatly deteriorated the cavitation resistance of the cermet coatings.